桥式起重机维护及保养

起重机日常维护与保养

Routine Care and Maintenance of Crane

（一）机构的润滑Lubrication of Mechanism 起重机设备润滑情况的好坏直接影响起重机各机构的正常运转，同时与延长机件的寿命和促进安全生产有密切的关系。因此，使用和维修人员必须经常检查各润滑点的润滑情况，按时用油枪通过各润滑点的油杯加油。

The lubrication condition of crane equipment directly affects the normal operation of crane mechanisms and is closely related to extending the service life of the mechanics and promoting safety in production. Therefore, the use and maintenance personnel must carry out regular checks on all lubrication points and fuel on time with oil gun through oil cups of the lubrication points. 1．起重设备各润滑点的分布

1.Distribution of lubrication points of hoisting equipment

①吊钩滑轮轴； Hook pulley spindle

②固定滑轮轴（小车架上）；Fixed pulley spindle （on the dolly frame）③钢丝绳；

Steel rope

④各减速器； Reducers

⑤各齿轮联轴器； Gear couplings

⑥各轴承箱（包括车轮组、卷筒组）；Bearing boxes （including group wheel and group reel）

⑦电动机轴承； Motor bearing

⑧制动器各节点和轴栓； Nodes and axle bolts of brake

⑨电缆导电中滑车的轴承； Pulley bearing of electric cable ⑩抓斗各铰点的轴。 Shafts

of grab hinge joints

2．润滑条件与润滑材料

2.Lubricating condition and materials 起重设备必须采用合适的润滑油脂，定期润滑和及时更换，润滑装置和各润滑点必须保持清洁。下表所列为各机构主要零部件润滑时间的一般规定和推荐用的润滑材料：

Appropriate lubricant grease must be used for hoisting equipment, which should be regularly lubricated and timely replaced; lubrication equipment and the lubrication points must be kept clean. The following table lists the general regulation on lubrication interval time

注：表中所列 Q/SY 系列系辽宁省营口市润滑油脂厂厂标代号； SYB 系石油部部颁标准代号。

Note: the listed Q / SY series is the blem code of Lubricating Oil and Grease Factory in Yingkou City, Liaoning Province; SYB is the ministerial standard code of the

Petroleum Department.

（二）机构设备的维护和保养Care and Maintenance of Mechanical Equipment 1．钢丝绳

1. Steel rope ①．报废标准：按 GB6067-85《起重机械安全规程》中有关规定执行。Discard standard: according to the relevant provisions in GB6067- 85 “ Hoisting Machinery Safety Regulations ”.

钢丝绳使用的安全程度由下列项目判定（见 2.5.1~2.5.10款）

The security level of steel rope is determined by the following items （ refer to

2.5.1~2.5.10）

a、断丝的性质和数量； Nature and number of filament breakage

b、绳端断丝； Rope-end filament breakage

c、断丝的局部聚集； Partial aggregation of filament breakage

d、断丝的增加率； Increasing rate of filament breakage

e、绳股断裂； Strand breakage

f、由于绳芯损坏而引起的绳径减小； Reduction of rope diameter caused by the

damage of rope core

g、弹性减小； Reduction of elasticity

h、外部及内部磨损； External and internal wear and tear

i 、外部及内部腐蚀； External and internal corrosion

j、变形； Deformation

k、由于热或电弧造成的损坏。 Damages caused by heat or electric arc 所有的均应考虑以上各项因素并遵循各自的标准。然而，钢丝绳的损坏往往是由各个因素综合积累造成的，这就应由主管主管判别并决定钢丝绳是报废还是继续使用。

All the above factors should be taken into account and follow their respective standard. However, the damage of steel rope is often caused by the accumulation of various factors, which requires the superintendent to judge and decide to discard or continue to use the rope.

在所有情况下，检验人员应弄清钢丝绳的损坏是否由机构上缺陷所造成，如果是这样，应建议在换新钢丝绳之前消除这缺陷。

In all cases, inspectors should ascertain whether the rope damage is caused by mechanism defects; if so, it should be recommended to eliminate the defect before replacing the rope.

2.5.1绳端断丝 Rope-end filament breakage 当绳端或其附近出现断丝时，即使数量很少也表明该部位应力很高，可能是由于绳端安装不正确造成的，应查明损坏原因。如果绳长允许，应将断丝的部位切去重新合理安装。

When filament breakage occurs at the rope end or nearby, even if there is only a small number, it also indicates that the stress of that part is very high, which may be because of the incorrect installation of rope end; the cause of damage should be identified. If the rope length allows, cut out the site where filament breakage occurs and conduct a reasonable re-installation.

2.5.2断丝的局部聚集 Partial aggregation of filament breakage

如果数年丝紧靠一直形成局部聚集，则钢丝绳应报废。如这种断丝聚集在小于 6d 的绳长范围内，或者集中在任一支绳股里，那么，即使断丝数比表列的数值少，钢丝绳也应予以报废。

If for years the filaments gather forming partial aggregation, the rope should be scrapped. If the filament breakage aggregates within the scope of rope length less than 6d, or concentrates in any one strand, even if the number of broken wires is less than the value listed in the table, the steel rope should also be scrapped.

2.5.3断丝的增加率 Increasing rate of filament breakage 在某些使用场合，疲劳是引起钢丝绳损坏的主要原因，断丝则是在使用一个时期以后才开始出现但断丝数逐渐增加，其时间间隔越来越短。在此情况下，为了判定断丝的增加率，应仔细检验并记录断丝增加情况。判明这个“规律”可用来确定钢丝绳未来报废的日期。

In some use occasions, fatigue is the main reason causing the damage of steel wire rope; filament breakage begins to occur after a period of time, but the number of broken wires gradually increases and its interval time becomes shorter and shorter. In this case, in order to determine the increasing rate of broken wires, carefully inspect and record the increase of broken wires. Identifying this "law" can be used to determine the future scrapping date of steel rope.

2.5.4绳股断裂 Strand breakage 如果出现整根绳股的断裂，则钢丝绳应报废。

If the breakage occurs to a whole strand, the steel rope should be scrapped.

2.5.5由于绳苡损坏而引起的绳么减小Reduction of rope diameter caused by the damage of rope core

当钢丝绳的纤维芯损坏或钢芯(或多层结构中的内部绳股)断裂而造成绳显著减小时，钢丝绳应报废。

When the fiber core of steel rope is damaged or steel core (or the internal strand in multi-layer structure) fractures and it causes significant reduction of rope diameter, the rope should be scrapped.

微小的损坏，特别是当所有各绳股中应力处于良好平衡时，用通常的检验方法可能是不明显的。然而这种情况会引起钢丝绳的强度大大降低。所以，有任何内部细微损坏的迹象时，均应对钢丝绳内部进行检验予以查明。一经证实损坏，则该钢丝绳就应报废。

Minor damage, especially when the stress of all the strands is in good balance, may be unobvious with the usual test method. However, this may greatly reduce the strength of steel wire rope. Therefore, when there are any signs of internal slight damage, the interior of steel rope should be inspected to make clear the signs. Once the damage is proven, the rope should be discarded.

2.5.6弹性减小 Reduction of elasticity 在某范些情况下，钢丝绳的弹性会显著减

小，若继续使用则是不安全的。

In some cases, the elasticity of steel rope will be significantly reduced and continued use would be unsafe.

钢丝绳的弹性减小是较难发觉的，如检验人员有任何怀疑，则应征询钢丝绳专家的意见。然而弹性减小通常伴随下述现象：

It is rather difficult to find the reduction of the wire rope elasticity; if inspectors have any doubts, they should consult the rope expert. However, the reduction of elasticity is usually accompanied by the following phenomenon:

a、绳径减小； Reduction of rope diameter

b、钢丝绳捻距伸长； Prolonged lay length of steel rope

c、由于各部分相互压紧，钢丝之间和绳股之间缺少空隙；

As various parts are compressed against each other, there is lack of gap among wires and strands.

d、绳股凹处出现细微的褐色粉末；

Fine brown powder appears in the place of strand cavity.

e、虽未发现断丝，但钢丝绳明显的不易弯曲和直径减小比起单纯是由于钢丝磨

损而引起的也要快得多。这种情况会导致在动载作用下突然断裂，故应立即

报废。

Although broken wires are not found, the elasticity reduction caused by obvious difficulty of bending and diameter reduction is quicker than that simply caused by wear and tear of wires. This situation will result in a sudden fracture under dynamic load, so the rope should be immediately scrapped. 2.5.7外部及内部磨损 External and internal wear and tear

产生磨损的两种情况： The two situation causing wear and tear:

a、内部磨损及压坑 Internal wear and indentation 这种情况是由于绳内各个绳股和钢丝之间的摩擦引起的，特别是当钢丝绳经受弯曲时更是如此。

This situation is due to the friction among strands and wires in the rope, especially when the wire rope is subject to bending.

b、外部磨损 External wear 钢丝绳外层绳股的钢丝表面的磨损，是由于它的压力作用下与滑轮和卷筒的绳槽接触摩擦造成的。这种现象在吊载加速和减速运动时，钢丝绳与滑轮接触的部位特别明显，并表现为外部钢丝磨成平面状。

The wear on the wire surface of the outer strands in the rope is caused by the friction in the contact with the rope groove of pulley and reel under its pressure. When the suspended load is acceleration and deceleration movements, this phenomenon is particularly evident at the contact area of wire rope and pulley and it is shown that the external wires are worn into a planar.

润滑不足，或不正确的润滑以及还存在灰尘和砂粒都会加剧磨损。

Lack of lubrication, improper lubrication, or the existence of dust and grit will accelerate the wear.

磨损使钢丝绳的断面积减小因而强度降低。当外层钢丝磨损达到其直径的 40%时，钢丝绳应报废。

The wears reduce the sectional area of steel rope and thus reduce the strength of the rope. When the wear of outer wire reaches 40% of its diameter, the rope should be scrapped.

当钢丝绳直径相对于公称直径减小 7%或更多是，即使未发现断丝，该钢丝绳也应报废。

When the diameter of steel rope decreasesb y 7% or more compared to the nominal diameter, even if no broken wire is found, the wire rope should also be

scrapped.

2.5.8外部及内部腐蚀 External and internal corrosion 腐蚀在海洋或工业污染的大气中特别容易发生。它不公减少了钢丝绳的金属面积从而降低了破断强度，而且还将引起表面粗糙并从中开始发展裂纹以致加速疲劳。严重的腐蚀还会引起钢丝绳弹性的降低。

Corrosions will happen very easily in the sea or in the atmosphere subjecting to industrial pollution. It not only reduces the metal area of the wire rope and thus reduces the breaking strength, but also will cause a rough surface which may be developed into cracks accelerating fatigue. Serious corrosion can also reduce the reduction of rope elasticity.

2.5.8.1外部腐蚀 External corrosion 外部钢丝的腐蚀可用肉眼观察。当表面出现深

坑，钢丝相当松弛时应报废。

The corrosion of external wires can be observed with the naked eye. When there is deep pit on the surface and the wire is quite loose, the rope should be scrapped.

2.5.8.2内部腐蚀 Internal corrosion 内部腐蚀比经常伴随它出现的外部腐蚀较难发现。但下列现象可供识别： The internal corrosion is difficult to find than the external corrosion often accompanying the internal corrosion. However, the following phenomena can be identified:

a、钢丝绳直径的变化。钢丝绳在绕过滑轮的弯曲部位直径通常变小。但对于静止

段的钢丝绳则常由于外层股出现锈积而引起钢丝绳直径的增加。

The change of wire rope diameter: The diameter of the bending part through the pulley usually decreases. But the diameter of steel rope in the still part usually increases due to rust accumulation of the outer strands.

b、钢丝绳外层绳间的空隙减小，还经常伴随出现个层绳股之间断丝。

The gap reduction between the outer wire ropes is also often accompanied by filament breakage in the single strand.

如果有任何内部腐蚀的迹象，应由高度重视人员对钢丝绳内部检验。若确认有严重的内部腐蚀，则钢丝绳应立即报废。

If there are any signs of internal corrosion, the inspection of the steel rope interior should be attached great importance to by testing personnel. If serious internal corrosion is identified, the rope should be immediately scrapped.

2.5.9变形 Deformation 钢丝绳失去正常形状产生可见的畸形称为“变形”。这种变形部位可能引起变化它会导致钢丝绳内部应力分布不均匀。

Loss of normal shape and visible malformation of wire rope are known as "deformation". This kind of deformation may cause the uneven distribution of internal stress in the steel rope.

钢丝绳的变形从外观上区分，主要可分下述几种：

Distinguished from the appearance, the deformation of steel rope can be mainly classified as the following types:

2.5.9.1 波浪形 Wave-type 波浪形的变形是：钢丝绳的纵向轴线成螺旋线形状。这种变形不一定导致任何强度上的损失，但是变形严重即会产生跳动造成不规则的传动。时间长了会

引起磨损及断丝。

Wave-shaped deformation is: the vertical axis of the rope turns into the spiral shape. This deformation does not necessarily lead to any loss of strength, but serious deformation will lead to jumpiness and cause irregular transmission. Such deformation for a long time can cause wear and filament breakage.

出现波浪形时，在钢丝绳长度不超过 25d 的范围内，若 d1≥4d，则钢丝绳

3 应报废。

When the wave shape occurs and the length of the rope is no more than 25d, if d1

≥4d

, the rope should be scrapped.

式中 d 为钢丝绳的公称直径； d1 钢丝绳变形后包络直径。

In the formula d is the nominal diameter of steel rope; d1 refers to enveloping diameter after steel wire rope deforms.

2.5.9.2笼关畸变 Cage-type deformation 这种变形出现在具有钢芯的钢丝绳上。当外层绳股发生脱节或者变得比内部绳股长的时候就会发生这种变形。笼状畸变的钢丝绳应立即报废。

This deformation appears in the wire rope with steel core. When the outer strands become detached or become longer than the internal strands, the kind of deformation will occur. The rope deformed into cage shape should be immediately scrapped.

2.5.9.3绳股挤出 Strand extrusion 此种状况通常伴随笼状畸变一直产生。绳股被挤出说明钢丝绳不平衡。绳股挤出的钢丝绳应立即报废。

This situation usually occurs accompanying cage-type deformation. The strand extrusion means the imbalance of steel rope. The rope whose strand is extruded should be immediately scrapped.

2.5.90.4钢丝挤出 Wire extrusion 此种变形是一部分钢丝或钢丝束在钢丝绳背着滑轮槽的一侧拱起形成环状。这种变形常因冲击载荷而引起。若此种变形严重时，则钢丝绳应报废。

This kind of deformation is because part of the wires or wire tendons hog forming into ring shape on the side against the pulley groove. This distortion is often caused by impact load. If such deformation is severe, the rope should be scrapped.

2.5.90.5绳径局部增大 Partial increase of rope diameter 钢丝绳直径有可能发生局部增大，并能波及相当长一段钢丝绳。绳径增大通常与绳芯畸变有关(如在特殊环境中，纤维芯因受潮而膨胀) ，其必然结果是外层绳股产生不平衡，而造成定位不正确。绳径局部严重增大的应报废。

There is possibly partial increase of rope diameter and can spread to quite a long rope. The increase of rope diameter is usually associated with the distortion of the rope core (for example, in a special environment, the fiber core will inflate due to damp), and it will definitely lead to the imbalance of outer strands and incorrect positioning. The rope whose partial diameter is severely enlarged should be scrapped.

2.5.9.6扭结 Kink 扭结是由于钢丝绳成环状在不可能绕其轴线；转动的情况下被拉

紧而造成的一种变形。其结果是出现捻距不均而引起格外的磨损，严重时钢丝绳将产生扭曲，以致只留下极小一部分钢丝绳强度。

Kink occurs when the rope is tensed up in the rotation because the ring-like rope cannot wind around its axis. This will result in the unevenness of lay length and extra wear. When this situation is severe, the rope will be distorted and only a very small part of the rope strength remains.

严重扭结的钢丝绳应立即报废。

The steel rope having severe kinks should be immediately scrapped. 2.5.9.7绳径局部减小 Partial decrease of rope diameter 钢丝绳直径的局部减小常常与绳芯的断裂有关。应特别仔细检验靠绳端部位有无此种变形。

The partial decrease of rope diameter is often related to the fracture of rope core. Carry out particularly careful examination to check whether there is such deformation in

the rope-end part.

绳径局部严重减小的钢丝绳应报废。

The steel rope whose partial diameter severely decreases should be scrapped.

2.5.10.8部分被压扁 Parts flattened 钢丝绳部分被压扁是由于机械事故造的。严重

时，则钢丝绳应报废。

The parts of steel rope are flattened due to mechanical accident. If it is severe, the rope should be scrapped.

2.4.9.9弯折 Bending 弯折是钢丝绳在外界影响下引起的角度变形。

Bending is the angle deformation of steel rope caused under the outside influence.

这种变形的钢丝绳应立即报废。

The steel wire rope having such deformation should be immediately scrapped.

2.4.10 由于热或电弧的作用而引起的损坏 Damages caused by heat or electric arc

钢丝绳经受了特殊热力的作用其外表出现可资识别的颜色时，该钢丝绳应报废。

If influenced by special heat the steel wire rope shows identifiable color, the rope should be scrapped.

②．维护：钢丝绳应定期检查，必须特别注意钢丝绳末端的固定情况。为了避免钢丝绳迅速磨损，应保持钢丝绳处于良好的润滑状态。润滑前须用钢丝刷子刷去钢丝绳上的污物并用煤油清洗，再按规定用热油润滑。

Maintenance: wire rope should be regularly checked and special attention should be paid to the fixation situation of the rope end. In order to avoid rapid wear of steel wire rope, wire rope should be maintained in good lubrication. Before lubrication, use steel wire brush to rod the dirt on the rope, wash it with kerosene, and then conduct lubrication with hot oil according to the regulation.

③．更换：更换新的钢丝绳必须符合原设计型号、规格及钢丝绳公称抗拉强度等要求。钢丝绳禁止接起来使用。钢丝绳压板绳夹等处螺检必须坚固牢靠。

Replacement: The new wire rope must be consistent with the original design model, specifications, nominal tensile strength of wire rope and other requirements. It is prohibited to use the connected steel rope. The bolts at pressure pad, rope clamp, etc. must be firm and solid.

2．传动轴

2. Propeller shaft

1

轴的弯曲度不得超过1·1（1 为轴的有效长度），超过此值时应校直或换 2000

新轴。尤其是高速轴，弯曲度过大会产生振动。但允许低速轴的弯曲度超过1

1·1（1 为轴的有效长度）或超过 1mm 才予以更换。

1000

1

The curvature of the shaft should not exceed ·1 (1 represents the effective

2000

length of the shaft), and the shafts should be aligned or replaced if the curvature exceed the value, especially the high-speed shaft, vibration will appear when the curvature is too big. But the curvature of low-speed shaft is allowed to exceed

1

·1 (1 represents t he effective length of the shaft) or the shaft should be replaced only

when the curvature exceeds 1mm.

3．轴承

3.Bearing

轴承应保持良好的润滑状态。重新涂油前，轴承应当用汽油洗净，注意涂油量应为轴承体空腔的三分之二。正常情况下，轴承温升不超过 60 70 ，轴承的音响均匀。当轴承的温升过高、噪音很大时，必须检查，如发现轴承内外圈滚道、滚珠(柱)表面产生磨损条、剥落小坑、裂纹或轴承径向间隙增大到 0.2 毫米时，应予以更换。

The bearing should be kept in lubrication state. Before re-oil, the bearing should be cleaned with petrol, and the oil amount should be 2/3 of the cavity of bearing. Under normal circumstances, the elevated temperature should not exceed 60 70 ， and the sound of bearing should be even. The bearing must be inspected when the temperature is too high and the noise is too big and should be replaced when feather wear, point corrosion or crackle are found on the inner or outer ring raceway or on the surface of the ball (column) or the diametral clearance of the bearing increases to 0.2mm.

4．制动轮

4.Brake wheel 制动轮的制动磨擦面不应有缺陷和油污，制动轮磨损超过 5mm 或表面磨出大于 4mm 深的沟槽时应报废。

There should be no deficiency or greasy dirty on the braking friction surface of the brake wheel. The brake wheel should be discarded as useless when the attrition exceeds

5mm or there is groove deeper than 4mm worn on the surface.

因使用不当造成键槽扩宽的(不包括滚键)制动轮允许在原键槽位置错开120°再插键槽一次继续使用。但安装后的制动轮径向跳动不得超过下表的规定。

Brakes whose keyways (exclude rolling key) are widened due to improper usage is allowed to be continuously used by staggering 120 at the origina°l keyway position and inserting a keyway once. But the radial runout of the installed brake wheel should

not exceed the regulations in the following table.

5．吊钩

5.Lifting hook

①报废标准

①Scrapping standards 吊钩出现下述情况之一时，应报废： When one of the following situations occurs, the lifting hook should be discarded:

a．裂纹。

a.Crackle. b．危险断面磨损达原尺寸的 10%。

b.The attrition of the critical section reaches 10% of the original size. c．开口尺寸比

原尺寸增加 15%。

c.The opening size increases by 15% as compared with the original size. d．扭转变形

超过 10 。

d.The torsional deflection exceeds 10. e．危险断面或吊钩颈部产生塑性变形。

e.Plastic deformation is found on the critical section or hook neck. f．板钩衬套磨损

达原尺寸的 50%时，应报废衬套。

f.When plate hook bushing is worn by 50% of the original size, the bushing should be discarded.

g．板钩心轴磨损达原尺寸的 5%时，应报废心轴。

g.When the plate hook arbor is worn by 5% of the original size, the arbor should be discarded.

②板钩的铆钉松动数达总数的 10%时，应更换铆钉。

②When 10% of the rivets of the plate hook loose, the rivets should be replaced. ③

保护

③Protection a．禁止在钩上进行补焊；

a.Strictly forbid to make repair welding on the hook; b．每年至少检查一次吊钩螺母，吊钩钩柄的螺纹连接，当有锈蚀并起泡时即应更换；

b.The nut of lifting hook and the screw joint should be inspected at least once every year. They should be replaced immediately when there is corrosion and blister;

c．用于水爆清砂或其它有经常腐蚀场合的吊钩，应增设防护罩以防止腐蚀性物质浸害吊钩柄、吊钩螺母等。

c.Protection covers should be added on the lifting hooks used for water explosion blast cleaning or used in other corrosion occasions to avoid corrosive substance eroding lifting hook handle and lifting hook nuts and so on. 6．滑轮

6.Pulley

①报废标准

①Scrapping standards 滑轮出现下述情况之一时应报废： When one of the

following situations occurs, the pulley should be discarded: a．裂纹。

a.Crackle. b．轮槽不均匀磨损达 3mm。

b.Uneven wear of groove reaches 3mm. c．轮槽壁厚磨损达原壁厚的 20%。

c.The wall thickness of the groove is worn by 20% of the original thickness. d．因磨

损使轮槽底部直径减少量达钢丝绳直径的 50%。

d.The diameter of the groove bottom is worn by 50% of the diameter of steel wire rop

e.

e．其它会损害钢丝绳的缺陷。

e.Other deficiency damaging the steel wire rope.

②保护

②Protection a．定期检查滑轮组的润滑情况，保证其转动灵活。

a.Inspect the lubricating situation of the pulley block regularly and ensure its flexible rotation.

b．禁止将吊钩斜吊或歪吊，因为它是促使滑轮过早损坏的主要原因。

b.Strictly forbid to be hung inclined or crooked because it is the main reason for the premature failure of pulley.

7．车轮

7.Wheel

①报废标准

①Scrapping standards 车轮出现下述情况之一时应报废： When one of the

following situations occurs, the wheel should be discarded: a．裂纹。

a.Crackle. b．轮缘厚度磨损达原厚度的 50%。

b.The wheel flange is worn by 50% of the original thickness. c．轮缘厚度弯曲变形达

原厚度的 20%。

c.The bending deflection of the wheel flange reaches 20% of the original thickness.

d．踏面厚度磨损达原厚度的 15%。

d.The wheel thread is worn by 15% of the original thickness; e．当运行速度低于

50m/min 时，椭圆度达 1mm；当运行速度高于 50m/min 时，椭圆度达 0.5mm时。

e.When the running speed is lower than 50m/min and the out-of-roundness reach 1mm; when the running speed is higher than 50m/min and the out-of-roundness reach

0.5mm.

②保护

②Protection 及时排除啃轨、打滑或三角腿现象。

Eliminate the gnaw rail, slippage or triangle leg in time.

③更换

③Replacement

安装后的新车轮组应满足本使用说明书“五、安装与调试”中对车轮组安装的要求，同时应保证车轮组转动灵活。

After installation, the new wheel set should meet the requirements for the installation of wheel set in the “Ⅴ. Installation and Commissioning ”o f this instruction manual. Meanwhile, should ensure the flexible rotation of the wheel set. 8．联轴器

8.Coupling

①报废标准

① Scrapping standards a．齿轮联轴器出现裂纹、断齿或齿厚磨损量达原厚度的 15%

之一时。

a.Crackle, broken perforation is found on the gear coupling or the gear is worn by of the original thickness.

b．弹性联轴器出现弹性体老化，或是直径减小 2mm 时。

b.The elastomer ageing occurs on the spring coupling or the diameter of the coupling has reduced by 2mm.

c．万向联轴节十字架上的轴套磨损比原孔径增大 5%或花键磨损量达原齿厚的 15%时。

c.The shaft sleeve on the universal joint crucifix is worn and increases by 5% of the original bore diameter or the spline is worn by 15% of the original gear thickness.

②保护

② Protection 主要检查其润滑、密封是否良好，轴向位移是否在要求的范围内。

Mainly check whether the lubrication and seal is good or the axial displacement is within the required scope.

9．卷筒组

9.Winding drum group

①报废标准

① Scrapping standards 卷筒出现裂纹或是筒壁磨损达原壁厚的 20%时应报废。

When the crackle found on the winding drum or the drum wall is worn by 20% of the

original thickness, the winding drum should be discarded.

②保护

② Protection a．定期检查钢丝绳在卷筒上的排列状况，发现问题及时解决；

a. Inspect the arrangement of the steel wire rope on the winding drum regularly; problems should be solved immediately after found.

b．定期给钢丝绳涂润滑油，防止卷筒与钢丝绳干磨擦；

b. Put lubricating oil on the steel wire rope regularly to avoid dry friction between winding drum and steel wire rope;

c．每次大修时应彻底清洗内齿盘，装配时应加充足够的润滑脂；

c.The inner gear disc should be cleaned thoroughly every time overhaul, adequate lubricating oil should be filled when assembly.

d．对于四绳抓斗卷筒，当提升卷筒更换时，则开闭卷筒必须更换，但允许只更换开闭卷筒。

d.For the winding drum with four-rope grab, when replace the hoisting drum, the open and close drum must be replaced. But the open and close drum allowed to be replaced only. 10．轨道

10.Rail

①起重机轨道与小车轨道一年至少检查两次；

① The crane track and trolley track should be inspected at least twice one year.

②转产的固定是否良好，焊接压板的灶缝有无开裂，螺栓压板的螺母有否松动，轨道与承轨梁及主梁上盖板是否贴紧；

② Whether the fixation of transition to production is good, the welded joint of the welding pressure plate dehisces, the nut of bolt pressure plate looses and the track is kept close to upper cover plate of main beam and track-bearing beam;

③轨道的安装、调整详见本使用说明书“五、安装与调试”的要求；

③Details of the installation and adjustment of the track see the requirements in the Ⅴ“. Installation and Commissioning” of this instruction manual.

④更换轨道时，不允许使用氧—乙炔焰切割轨道压板；

④When replace the track, using oxy-acetylene flame to cut track pressure plate is not permitted;

⑤焊接时严禁在轨道上打火；

⑤When welding, it is not allowed to strike fire on the track;

⑥轨道踏面上严禁有油污附着。

⑥Oil dirty is forbidden to be adhere to the track thread. 11．制动器

11.Brake

①检查：起升机构的制动器应每班检查，运行机构的制动器不少于 2~3 天检查一次。检查时应注意：制动系统各部分应有准确的动作，轴栓不可有卡阻现象。闸瓦正确地贴合在制动轮上，闸瓦的衬料应良好。闸瓦张开时在制动轮两侧的间隙应处处相等。

① Inspection: The brake of the hoisting mechanism should be inspected every shift and that of running mechanism should be inspected at least once every two or three days. When inspect, special attention should be paid to the following matters: all parts of brake system should act preparedly, the bolt can not be jammed. The brake shoe should integrate closely with the brake wheel correctly and the packing material of the brake shoe should be good. When the brake shoe opens, the clearance between the brake shoe and

two sides of the brake wheel should be everywhere equidistant. 接通电流以检查闸瓦的张开情况，如发现不正常时，应进一步检查匹配推动器的工作是否正常。

Switch the current on to check the opening condition of the brake shoe, if found out of order, should further check whether the matching pusher is working normally.

检查制动力矩，起升机构的制动器必须可靠地支持额定起重量的 1.25 倍。运行机构的制动器，应能及时刹住大车和小车，但也不宜调整过紧，以免车轮严重打滑或引起振动和冲击。

Inspect the brake torque, the brake of hoisting mechanism must support 1.25 times of rated load lifting capacity reliably. The brake of running mechanism should be able to stop the cart and trolley, but it inadvisable to be adjusted over tight to avoid severe slippage of wheel or causing vibration and shock.

闸瓦衬料磨损超过 50%时，应即更换。制动轮表面应光洁，并定期用煤油抹布清除污物。

The packing material of the brake shoe should be replaced when it is worn by more than 50%. The surface of the brake wheel should be smooth. Clear the dirt up regularly with kerosene wiper.

②调整：如制动轮工作时出烟或发生焦味，即表示闸瓦和制动轮的温度过高 (制动轮温度不应超过200℃)，此时必须调整闸瓦和制动轮之间的空隙并使之相等。

② Adjustment: If the brake wheel gives smoke or burning smell off when it runs, it means that the temperature of brake shoe and brake wheel is too high (the temperature should not exceed 200℃), and at this time, should adjust the clearances between brake shoe and brake wheel and make them equivalent.

现通用桥式起重机一般选用 YWZ 型电力液压块式制动器和直流电磁制动器，其调整和使用均可参见配套生产厂家的使用说明书。

Current general-purpose overhead crane always uses YWZ type electro-hydraulic double-shoe brake and DC electromagnetic brake, and their installation and usage can see the instruction manual of supporting manufacture. 12．减速器及齿轮副：

12.Reducer and gear pair:

①齿磨损：分跑合性磨损与磨料性磨损两种。对前者主要以提高齿面光洁度，对后者以及时清除润滑油(脂)中的细砂、金属屑等机械杂质的方式给予改善。齿磨损是开式齿轮的主要破坏形式，应加以保护罩，防止灰尘落入。允许的极限磨损量一般为原齿厚的10%(重级、超重级起升机构)或 16%(中级、轻级机构、开闭机构)或 25%(其它机构)。

① Gear wear: it includes running-in wear and abrasive wear. For the former, mainly improve the smooth finish of the gear surface; for the later, improve the method for removing the bank sand, metal filings and other mechanical admixture in the lubricating oil (grease). The gear wear is the main destruction form of the exposed gear. Protective cover should be added on the gear to avoid dust falling into. The limit of allowance for wear is generally 10% of the original gear thickness (heavy, super heavy hoisting mechanism) or 16% (intermediate, light mechanism and open and close mechanism) or 25% (other mechanisms).

②齿点蚀：这是最常见的破坏形式，当点蚀剥落面积超过齿全部工作面积的 30%以及剥落的坑沟深度超过齿厚的 10%时应更换。

② Gear pitting: this is the most common destruction form. The gear should be replaced immediately when the pitting area exceeds 30% of the whole working area of the

gear and the pitting depth exceeds 10% of the gear thickness.

③齿胶合：主要原因是润滑油末形成连续油膜魔鬼发热所致。为防止胶合，必须使用工业齿轮油 50 号(冬天)或 100、120号(夏天)，不得用其它机器油。加油量按探油针的刻线所示。有时因锥形轴承未顶紧，轴向窜动过大，也会造成齿面局部接触产生胶合，应针对弊病，加以消除。已胶合的齿轮不得再用，应更换。

③Gear gluing: the main reason is caused by the lubricating oil not forming continuous oil film. To avoid gluing, must use industrial gear oil No.50 (in winter) or

No.100, 120 (in summer); using other engine oil is not permitted. The oil amount should be added according the scribed line on the inventory probe. Sometimes, because the cone bearing does notb ear tight and the axial float is too large, it will cause gear surface local contact and gluing. The gluing should be eliminated aiming at malpractice. The glued gears should not be reused and should be replaced.

④齿表面塑性变形：在低速重载情况下齿面很容易发生这种现象。应及时锉光棱脊，提高润滑油粘度或更换齿轮。更换齿轮时应适当提高齿面硬度。

④Plastic deformation on the surface of gear: under the low-speed over load condition, this will easily occur on the gear surface. The strip edge should be filed smooth to improve the viscosity of lubricating oil or change gear. When replace the gear, should appropriately raise the hardness of the gear surface.

⑤齿断裂：齿断裂主要发生在经过淬硬的齿轮上，有过载断裂和疲劳断裂两种。对前者主要应防止短期突然过载，对后者要经常检查齿根是否有裂纹，如发现裂纹则及时更换。

⑤Gear fracture: gear fracture mainly occur on the hardened gear, including overload breakage and fatigue fracture. For the former, mainly prevent sudden overload, and for the later, frequently check whether there is crackle on the gear root. The gear should be replaced immediately after the crackle is found.

⑥噪音及撞击声：主要决定于加工精度和装配精度，在检修或更换时，对闭式减速器应达到不低于 GB10095 中规定的 887 级，对开式齿轮不低于 998 级。装配后，在未加油时作空运转跑合，并作如下观察和判断：

⑥Noise and impact sound: mainly contingent on the machining precision and assembling accuracy. When overhaul or replace, close type reducer should not less than grade 887 stipulated in the GB10095, the exposed gear should not less than grade 998. After assemble, make it run idle when the oil has not be added, and make following observation and judgments:

a．接触带一般在齿节圆附近，在齿长方向必须达到 60%(闭式) 或 50%(开式)，或齿高方向未达到 45%(闭式)或 40%(开式)，但已形成一条或两条以上均匀线时，即认为是可以的，待加载跑合后就可达到上值。

a. The contact zone is generally around the pitch circle. When the gear length direction must reach 60% (close type) or 50% (expose type), or gear height has not reached 45% (close type) or 40% (expose type), but one or two even lines have formed, it should be regarded appropriate and will reach upper value after load running.

b．出现断续而清脆的撞击声，主要是在某个齿上有疤，经查找出后用细锉或油石打磨光即可。

b. There is discontinuous but ringing impact sound. It is mainly because there is a scar on a certain gear; it merely needs to be rounded off with fine file or oil stone after it is

found out.

c．噪音大但还均匀，主要是齿尖啃齿根，一般将齿顶尖角用细锉倒钝即可消除。

c.The noise is loud but even. It is mainly because the gear top gnaws the gear root. It merely needs to abate sharp corner of gear top with fine file.

d．出现不均匀的噪音，主要是齿斜角不正或装配歪斜，一般不好再修复，应报废换新的。当用锥形轴承时，锥面未顶紧，也会出现这种情况，此时用调整螺丝顶紧即可。

d.There is uneven noise, mainly because the gear bevel angle is not straight or assembling is crooked, which is not easy to repair. Old gears should be discarded and new ones should be changed. When use cone bearing and the conical surface is not bear

tight ， this will be also occur. At this time, it merely needs to bear tight with adjusting crew.

⑦减速器漏油：减速器上、下壳的连接螺栓、放油塞、视油盖螺栓未旋紧及密封胶失效时，均可造成润滑油泄漏，可采取如下措施予以改善或解决：

⑦Oil leakage in reducer: when the connecting bolt, oil drain plug and oil sight cap bolt on the upper and lower shell of the reducer are not screwed up and the sealant loses efficacy, may cause lubricating oil leakage. It can be improved or solved by taking the following measures:

a．更换失效的皮垫、环，并坚固减速器各部位螺栓；

a. Replace the deactivated leather packing and ring, and fast the bolt on all parts of the reducer.

b．重新涂密封胶。将接合面、瓦盖处失效的密封胶剥充或用醋酸乙酯和汽油各50%，或丙酮、酒精清洗干净后，凉干涂以均匀的密封胶，待3~5 分钟后

合箱(对于非干性粘合型密封胶，等的时间可长点)拧紧各处螺栓，过 24 小时左右后再次紧固螺栓即可投入使用。

b. Recast the sealant. Shuck off the deactivated sealant on the mating face and tile lid. Or clean them with acetone, ethanol, or ethyloleate and petrol, each of them accounting for 50%, and then dry them by airing and coat sealant on them evenly. Assemble mould after 3-5 minutes (For non-drying bonded sealant, we can wait longer). Screw all bolts down and tighten them again after about 24 hours. Then it can be put into operation.